Process of making cement.



H. L. DUNCAN,

PROCESS OF MAKING APPLICATION FILED NOV. 13, 1,1 1 3,606.

CEMENT.

1903. RENEWED MAR. 10, 1914.

Patented 0ct.'13, 1914;

INVENTOR MWTTORNEYS oniTED STATES PATENT. OFFICE. v

HARRYL. DUNCAN, or New YonK, N. Y.

PROQESS OF MAKING CEMENT.

Specification of Letters Patent. at f Oct 13 1914.

Application filed November 13, 1903, Serial No. 180,996. Renewed March 10, 1914. SeriaLNc. 823,797.

To all whom it may concern:

Be it known that I, HARRY L. DUNCAN, a citizen of the United States, and resident of New York city, in the borough of Brooklyn, county of Kings, and State of New York, have invented certain new and useful Improvements in Processes of Making Cement,

manufacture of Puzzolanic slag cement in that it is not necessary to add hydrated lime product in the manufacture of gray pig iron,

seems to be best adapted for this process and this high limed slag, preferably contains to of lime and not more than of silica. Basic slag of this description when allowed to cool in large masses in air sometimes decrepitates spontaneously into an impalpable powder.

Basic blast furnace slag may be treated so as to convert the same into material containing considerable proportions of active slag cement materiah Usually in the commercial operation this active cement material is not formed in an absolutely pure state, although when'water granulated furnace slag is roasted up to a plastic condition.

which usually corresponds with a temperature of about 1200 centigrade and then quickly cooled a comparatively pure active cement material is formed. This active material does-not decrepitate' in air and it seems to have a crystalline structure as is evidenced by the fact that it polarizes light.

The annealing process to which the slag has been subjected in forming active cenientmaterial aS herein described and by which the slag is maintained in the annealing or plastic temperature fora considerable length of time seems to effect a rearrangement of themolecular structure of the slag and a forma tion of compounds different from those'occurring in water granulated slag. WVhen active slag" cement material is finely ground,

slightly moistened, compressed into a cake and subjected to carbon-dioxid, a very con-.

sider'ablerise of temperature takes place,-

the compressed cake of-active material showmg "a rise of 40 or'so centigrade in an atmosphere of pure carbon-dioxid.

. Inert slag cement material may also be formed from blast furnace slag and this inert material is found in a comparatively pure condition "in water-granulated slag dined at about 200 centigrade.- This inert material-does not. decrepitate in air and seems to have a glassy or non-crystalline structure as indicated by the fact that it does not pol arize light. This inert material when finely ground, moistened, compressed into acake and treated with carbon-dioxid only gives an inconsiderable rise of tempera-ture as compared with that produced with active cement material.-

Inert material, such as chilled slag, or such as dried water granulated slag when mixed in a finely-powdered condition with about equal parts of active cement material, such as annealed molten furnace slag or roasted water granulated slag produces a valuable highlv cementitious material. The setting time of this 'cementitious mixture may, however, be regulated and its properties improved to some extent by an admixture of about ten per cent. of ordinary Portland cement and'also in some cases, if desired, by a further admixture of calcium sulfate to'the extent of a few per cent. y

In the accompanying drawings in'which the same reference numeral refers to similar parts in the several figures, Figure 1 is an elevation partly in section of an apparatus for carrying out this process. Fig. 2 is a partial elevatlon of a modified construc tion of apparatus. v A moving congealing surface may-be used in this process to congeal substantially molten furnace slag into a consistent stream for treatment. Intho drawings, a congealing roll 2 which should have a diameter of three or four feet or so is indicated for this purpose. This roll is preferably providedv with a water space 29 so that the congealing surface is kept at the proper temperature by a circulation of wateror other fluid, each of the trunnions being'formed with an aperture 20 -to secure this circulation. This roll which may be used with a cooperating congealing' surface of any description is indicated as being formed with the gear 17 in engagement with the pinion lo' secured to an electric motor 15 or-other adjustable speed driving device by which the speed of operating rolls in unison or the roll 1 may be positively rotated in any other desired way; The roll 1 is adjustable with respect to the other congealing roll so as to vary the distance between them, the trunnion block of the roll 1 being mounted in a slot and adjusted by heavy screws 51, as 'indi-1 'cated in Fig. 2. Besides the internal cooling means described, additional external cooling means may be employed, if desired. -'1:he cooling chamber 4 may be' formed partially inclosing the roll 1, the'npper end of the chamber being preferably closely adjacent the roll inthe form of a scraper to remove surplus cooling fluid. A number of spray pipes 22 are indicated within the chamber to furnish sprays of cooling fluid, such as Y water, to the roll, so that the heat of the roll is rapidly dissipated and removed from the exterior portions of the congealmg surface. The chilling surface is therebymore quickly cooled than if all the heatwere conducted inward to be absorbed by the internal water jacket. The amount of cooling fluids supplied through the spray pipes 22 is regulated by a suitable valve "26 in the supply pipe. A similar coolingchamber 5 is formed around the cooperating roll 2 and a number of spray pipes 38 are shown cooperating with the upper part of the roll n within the chamber furnished with the desired amount of cooling fluid by the valve 39 i in the-supply pipe. Another series of spray pipes 21 cooperate with the lower portion of this roll and the amount of fluid which they furnish 'is regulated by the valve 40 in the supply pipe with which they are connected. The surplus cooling fluid is removed from the chamber through the aperture 59 at thebottom.

'The scraper 56 is mounted adjacent the congealing roll 1 and disengages the congealed consistent stream from this roll and this stream 49 moves down the opposite surface of the congealing roll 2 and is disengaged therefrom by the upper scrapingedge of the conveyer 27. This conveyer is preferably formed with a suitable jacket 30 within which water, steam or other fluid may be maintained to regulate the tempera: ture of this conveyer. The consistent slag stream 49 may move directly from the stationary conveyer upon a' suitable moving conveyer 9 as indicated in Fig. 2 and this moving conveyer which may be in the form of a belt 9 of metal or other suitable material, is of any desired length and'fishould be long enough so that with the speed: used the desired annealin action takes place. "'This conveyer may, i desired, be inclosed in a suitable annealing chamber 58 indicated in Fig. 2 and suitable heating means may be used, if desired, to maintain the slag on the conveyer in the plastic annealing condition, preferably for a couple of minutes or so. If desired, however, a suitable breakermay be used to break up the consistent stream 49 and this breaker 6 may take the form of a rapidly rotating toothed wheel indicated in Fig.1 where it is shown mounted to rotate adjacent the end of the conveyer 27. The pieces of slag are thuspiled up on themoving-"co'nveyer 9 below, which is shown .as ,passing over the guide 57 and mounted upon distance. A spring-pressed tighteningfroll 33 be used in connection with this conveyer, this roll being shown as mounted in the slotted frame 34:. The drum 31 is rotated at the speed desired by any means and may be rotated by a suitable worm wheel 47 secured to the drum and engaged by the cooperating worm 46. This worm may be driven through the cone pulleys 8 from-the driving shaft 60 and the rate of movement of the material 50 onjthe conveyer is kept in the .thedrums 31, 32 spaced apart at a suitable ss conveyer- 9 may be thus regulated so that the annealing condition for the time desired, preferably acouple of minutes or so. Asuitable cooling chamber may be used adjacent the lower end of the conveyer 9, a numberof spray pipes 44: beingmounted in this I [chamber and supplied with the desired amount of cooling fluid by the valved supply pipe 11, the surplus water draining out of the chamber as indicated.

A number of treating jets may be mounted adjacent the conveyer to operate upon the slag material thereon. The jet pipes 23 extending parallel to the congealing rolls and which may be provided with a number of apertures along their length forthe discharge of.-.-fluid are mounted adjacent the conveyer-2T soas to supply jets of treating fluid, suchas steam, air, gas or water to the "slag. The fluid supplied to the upper jet pipe is controlled by the valve 25 and the fluid supplied to the twolower jet pipes 23 is controlled by a. similar separate valve, as indicated. Other jet pipes 24 are indicated by which other treating fluid, such as water, steam airor gas may be supplied, the amount of fluid issuing from the apertures in these jet pipes being controlled by the valve 26. Also, if desired, a similar perforated jet pipe 24 may be mounted adjacent the breaker 6 and may be furnished with fluid, preferably water or steam, the amount of which is controlled by -the valve 26. This fluid assists in rendering the breaker self clearih'g, speed of the breaker and thetreating fluid sprayed upon it preventing-the slag from sticking to it to an undesirable extent. Other jet pipes 42, 43 are indicated adjacent the conveyer and the amount of treating fluid supplied to these perforated pipes is regulated by the valve 11. It is, of bourse, understood that other jet pipes may be usedat other portions of the conveyer, if desired.

A suitable pulverizer is mounted adjacent the conveyer and the pulverizer may take the form of the heavy toothed wheel 13 rotated.

by suitable means adjacent the end of the conveyor. This wheel pulverizes the material which falls'down a suitable chute 35 to be cooled and removed. The rotary cooler 12 may be mounted to receive these particles of slag, the cooler being preferably rotated by any desired means and formed'with. the internally projecting ribs 37 to agitate the material and to rapidly cool the same in connection with the spray pipes 36' which furnish sprays of cooling fluid to the outside of the-cooler.

If desired, a suitable feed-roll may be employed to'positively feed the proper quantity of material to the congealing rolls. In

' Fig. 2 the feed roll 52 is indicated as being provided with a water space, each of the trunnions being formed with a suitable aperture 53 by which cooling fluid may be suppliedto the interior .of the roll. The outside of this feed roll is preferably formed with suitable corrugations 54: and also with annular grooves with which a suitable scraper 55 coacts to disengage the material from the roll. This feed roll may be rotated in the direction indicated by any desired .means and its trunnions are preferably ad- 'justable with respect to the congealing roll 2 with Which it cooperates.

tially molten slag 4:8 is sup-plied to the feed- The substaning roll by a number of spouts, each spout 3 being located as shown in the drawing. It is not necessary, however, in all cases to employ the separate feeding roll described,

since the positivefeeding forward of the material may be effected by slightly roughening the surfaces of the congealing rolls themselves, .if desired. The substantially molten slag may be supplied to the bite of the congealing rolls by a number of slag spouts, such as 3, which, as indicated in-Fig. 1, supplies a stream 48 of slag. The frame 45 of this apparatus cooperates with the congealing rolls and constitutes the sides of a slag trough which directs the substantially molten slag between the congealing rolls. This frame is continued. around the conveyer and may be provided with suitable doors, such as 7 and 14 for inspection or for the circulation of air or treating fluids through the apparatus.

Slag material containing considerable 'for more. convenient further treatment.

the high proportions of active cement material may i be produced on the apparatus described. The congealin-g rolls are preferably adjusted so that the consistent stream of slagniaterial is plastic when it issues from the'bite of the rolls andpreferably abouta quarter of an inch thick. This stream, which may be treated with fluid on the conveyer, preferably with air or steam, should be in the plastic condition while it is upon the moving conveyer and if the breaker is used the speed of the various parts of the apparatus i should be so adjusted that the slag is piled up on the moving conveyer-s'o that the dissipation of heat is prevented and the slag annealed by its own heat. This amount of slag 50 is thus annealed on the conveyer and the conveyor should be of such length and driven at such speed that the annealingaction lasts for several minutes to secure the best results: If desired, however, a suitable substantia ly inclosed annealing chamber may be formed above the conveyer and this chamber may be supplied, if .desired, with heated gases to insure the proper annealing of the slag. This annealing process should;

not continue so long however, that decrepitation of the'slag is effected and after annealing sufficiently the slag should be quickly cooled for this same reason. If an annealing chamber is employed in connection with the conveyer the temperature of the chamber should be so adjusted that the slag is pr0perly annealed by being kept substantially in the plastic conditio onthis same apparatus, the congealing rolls also they may be rotated somewhat faster. In this way, the stream of slag may be con-- v Inert slag cement material maybe made for this purposebeing preferably adjusted considerably closer together and if desired,

'gealed more thoroughlyandmayb'echilled to a substantially rigid cdndition when issuing from the congealing rolls. In passingover the conveyer, this slag may be treated with suitable fluid and, in eed, jets of cooling liquid, such as water, maybe freely used,

since after the slag has been cooled to a cer:

tain extent the contact of water does not. have a bad effect, the water not being absorbed as is the case when "the molten slag is run directly into water. v In producing inert cement material therefore, the con- .gealing rolls may be set as close together as a 16th or an eighth of an inch, the resulting stream of consistent material being treated first by steam, or air if desired, and then by 5 water jets to rapidly chill and cool the same,

the material being subsequently broken up,

The materials thus produced are finely V pulverized and mixed together in such proable variations may be made from these proportions. .An admixture of about ten per cent. of Portland cement may be made to the mixed slag product and a further admixture of one or two per cent-of calcium sulfate may be used to improve the setting proper.-

, ing. considerable portions of active material.

In this way; the resulting slag product may contain Without further admixture the proper proportions of active and inert ce- Inent materials.

' It is, of cou rse, understood that those fa miliarwith this art may make many changes in the number, character and'order of the steps of this process which have been described. This process may'also be carried out without using the particular apparatus which has been described herein, and furthermore, it is understood that it is not necessary to employ the particular kind of slag Whichhas been mentioned, since slag insome cases and indeed, slags containing considerable less lime may sometimes be used. I do not,.therefore,'desire to be limitedtothe details ofthe disclosure which has been made in this .case, but 'vlVhat I claim as new and what I desir to'z'secure by Letters Patent is set forth in the-annexed claims. 1

1. 1The-cement process, that consists in conjg'ealingsubstantially ,nolten furnace slag by :contact with, a congealing surface into a sheet of plastic material, in breaking up and annealing said' material and in subse quently pulverizing and cooling. the same to form,.slag material containing substantial proportions of active cement material; in treating furnace slag to produce inert ee- 5 ment'material; and in mixing substantial proportionsof said active. cement material, said, inert cement material, and Portland cement. v v

-'-.;2.-The .-cement process, that consists in congealingsubstantially molten furnace slag by -.contac,t'with a con'gealing roll into a sheetof plastic material, breaking up said material and in piling the same upon a con -veye1: to anneal. the same, and in subseso quently pulverizing' and cooling the same so as to form slag material containing substantial proportions ofiactive cement material.

3. The cement process, that consists inv v congealing substantiallyimolten furnace slag 5 into a stream of pl'astie'material, in breaking up and piling said material upon a con veyer, and in pulverizing and cooling said material to form slag material containing substantial .proportions of active cement material.

4. The cement process, that consists in congealing substantially molten furnace slag E into a stream of consistent material, in breaking up and piling said material upon a conveyer, and in subsequently cooling the same to form slag material containing substantial proportions of active cement ma' n material containing substantial proportionsof active cement material.

p 6. The cement process, that consists in congealing substantially molten furnace slag into a stream of consistent material, in treating said material with jets of impinging cooling fluid, in annealing said material while in a plastic condition andin subsequently cooling the same to form slag materialcontaining substantial proportions of active cement materiaL- 7 The cement process, that consists in forming a stream of consistent furnace slag of different composition may be employed v.

material, in treating said material with jets of impinging cooling fluid, in annealing raid material While in a plastic condition, and in subsequently cooling the same to formrslag material containing substantial proportions of active cement material.

8. The cement process, that consists in forming a stream of consistent furnace slag material, in annealing said material, and in subsequently cooling the same to form slag material containing substantial proportions of active cement material.

9. The cement process, that consists in forming'a stream of consistent furnace slag material, and in annealing said material to form slag material containing substantial proportions of active cement material.

10. The cementprocess, that consists in forming a stream of consistent furnace slag material, .in brgaking up and piling said material upon a conveyer, and in subsequently cooling the same to form slag material containing substantial proportions of actlve, cement material.

11. The cement process, that consistsin I congealing substantially molten furnace slag by congealing rolls into the stream of consistent material, in treating said material with fluid jets and in pulverizing the same to form slag material containing substantial proportions of inert cement material.

12. The cement'process that consists in forming a stream of consistent furnace slag thickness and in treating the same with innpinging fluid jets.

.' v .13. The cement process that consists in 'forming a stream of consistent furnace slag .jand in pulveriz'ing the same.

15. The cement process that consists in stream of consistent furnace slag -mater ial and in subsequent-1y treating the same with impinging fluid jets.

p '16. The cementprocess that consistsin congealing substantially "molten furnace slag intoa "stream of plastic material, in

breaking up said material, in piling said material together for .a definite time to anneal the same; and-in subsequently pulveri'zing and cooling said material to form slag material containing substantial proportions of active cement material.

17. 'Thefcement process that consists in congealing substantially molten furnace "slag into a stream ofplastic, material, in. anneaL' ing said material for a definite time and in subsequently pulverizing' and cooling the same to form slag material containing substantial proportions of active terial, I p v v 18. The cement process that consists .in forming a stream of consistent furnace slag cement mamate'ria'l and in annealing said material for.

a definite time to. form slag materialcon-z taining substantial proportions of active cement material. I a r 19, The cement 'fprocess that consists. in; forming plastic furnace slag material,;'. in annealing said material for a definite time and '-in subsequently cooling the same to form slag material containing substantial proportions of active-cement material.-

20. The cementprocess that consists in. forming substantially plastic furnace slag material and in annealing said material for 'a definite time to. form slag material containing substantial" proportions of active cement material. I Y 21. :The cement prooess'that consistsin forming substantially out. of contact .with

jets and" inicooling the. same. forming Without contact with moisture a i water a stream of consistent furnace slag material, in subsequently treating the .same

with fluid jets: and in. pulverizing and in cooling the same.

, .22. The cement process that consists in forming substantially out ofcontact with Water a -stream. of consistent furnace slag material, in treating the same with impinging jets and in cooling the same. 23. The cement process that consists in .congealing substantially molten furnace slag out of substantial contact with water in treatmg the same with impinging cooling 24. The cement process: thatkconsists' in breaking up and piling congealed heated 25, The cement process. that consists in v disintegrating and piling on a conveyer consist'ent heated furance slag to form thereon a pile of granular-material in annealing said slag material for a definite time and in isubsequently pulverizing and "cooling the same to form .slag material containing substantial roportions of active cement ma terial. 26; The cement processthat consists in water a pile 'of granulanconsistent heated furnace slag materlal, in annealing said: ma

terialfor a definite time and in subsequently pulverizingand cooling the same to form 27. The {cement process that-consists .i

.forming' a pile .of consistent granularlfui uniform thickness and in treating the same with impinging Witnesses:

J osnnn J. CoLLINs, Jnssm B. KAY;-

Duncan.

torming without substantial contact With' slag material cOntaining'substantial prop'orv tions of active cement materlal. p 

